dub tek

FINALLY found a complete solid front axle near me
Going to get it this week.....

So I have LOTS MOAR reading to do now....
I did see major fitment issues with a front IFS so i began looking into the SAS world..
The volume of info + parts + kits + such is WOW!!!


It also looks as tho my monetary investment is getting larger too
axle rebuild kits are $300+
Springs $300+
Hangers/shackles/hardware/UBolts + such $300+
High Steer $300+ (at least I have an 88' IFS steer box)
Brakes $200
F. drive axle work (adjust length) $150+
X2motor X2Transfercase mounts $200+
MISC Shifter rebuild parts $200+
Tcase axle flanges $100>??
3rd flanges $50>??
Shocks+hoop mounts >> Dont even know what to use yet....
Rear End springs + all that goodness (Maybe 63's!??) >>$$?
Driveline fluids ($150)


and about 50 other things I dont even know about yet...... HAHA
Im guessing a solid working week for this swap at this rate!!!

tundup93

If you get a sas kit its a lot cheaper. Wabfab has them on a good sale right now.

dub tek

As I shop Im seeing the light

Now its time to find a retailer with stock in hand for the kit
Also looking for swap parts... HD mounts Motor+Tcase


Im still reading on these multi drilled drive flanges..
I guess im a bit lost still.. HAHA
the all look to be for CV axles Front diff output

My question is this..
Is the flange at the front 3rd's the same on IFS and Solid?
AKA can I just have my drive shaft lengthened?

dub tek

Got some more goods in the mail

Made a large random parts order from my OE parts sources
- 22reTurbo motor mounts - shifter stuff - hardware - gaskets - ebrake cable - electric transfer fuel pump -

SAS kit is on ordered
Got my axle from a local guy on craigslist
needs a healthy cleaning > THEN i can start to rebuild it!!

Seams as tho Im rounding 3rd on the parts pile tho!!

dub tek

If you travel FaceBook online
Seams a good group of guys going on Toyotaholics

dub tek

Hey everyone.... Just want to start this by saying THANK YOU
Yotatech has been my BEST resource for info and such!!!!
Couldnt have gotten this far along without ya


A bit of quick history
This is my first real RIG if you will...
Had X2 other yotas in stock daily driver form....
Just did a bunch of maintenance and drove them around town



NOW for the build....
I traded the second owner of this truck a wooppppeedddd 2000 vw Jetta
So I feel I got a GREAT DEAL as I had about $5/600 in the vw..

^^ Day I brought it home

^^ Quick set of 31s off tirerack


Now
the truck was 100% stock other then Tbar crank/rear blocks/wheel-tire combo
Seeing as it had 242K and the 22RE knocked like a MOFO
I decided to investigate DIESEL motor swaps. > ALH TDI
(Now Im a vw technician by trade so my decision was easy)

Google led me to ACME ADAPTERS and this is the kit Im using
Bolts most vw diesels to 22re bolt pattern bellhousing

Now that the engine and adapter kit sorted it was time t double check clutch fitment...
Im using the provided flywheel from ACME and a 1250# aisin Plate & Disk combo


^^ Checking TDI & R151F bell housing

^^ NOT a fan of "Dual Drilled Flywheels"
So I made some pins and pressed them into the toyota pattern holes




^ Fitting Clutch


Next up was the transmission
Reading other build threads and seeing pics I knew about the fitment issues
Research showed 22RTE (R151F) Bell housing was a tad longer
I scored mine on ebay for $60!!!

Realizing the gearing for a diesel VS 22re isnt ideal
I did more reading and found the R series of transmission had some options
End result I have 1st&2nd from a V6 3rd+4th from the 22RE and 5th from a supra R154 for a bit more overdrive
In an attempt to keep the diesel happy at highway speeds. We Shall see....



Now for the dual transfer case
To get an R series gearbox to bolt to a GEAR driven transfer case
I used ADVANCED ADAPTERS kit..
Ordered it and some other goodies from lowrangeoffroad

Using a trail-gear.com kit for this...
Got it from Craigslist NEW in a box for $200 along with a spare gear drive case




^^ Bench work

^ Engine & Gearboxes



With the engine-gear box assembled it was time for install.....
An attempt to use IFS was NOT happening as the diff was IN THE WAY!!!



SO the SAS starts.....
Used an eliminator kit from Trailgear
Got it from frontier4x4 << BEST price on the net!!


^^ My $125 Front Axle from craigslist!!!!!!!!!!!
Its rough as im in ohio and everything gets wasted

^Pressure washed

^ Stripped


^^ Some welding

^^ Made shock mounts and upper gusset to the ball end
Used POR15 metal prep and semigloss on the axle


^^ "gutz"

WE ALL KNOW WHAT A SET OF GUTTED FRAME RAILS LOOKS LIKE SO ILL SAVE THOSE PICS!!!
haha



^ Drivers side





^^ Passenger side



PLEASE SEE BELOW.....

dub tek

Status as of thread start:
Have the engine + gearboxes mounted
Have most of the SAS complete.....
HOWEVER >>>> Im Having a few issues so I started the thread.......

My shackle angle is for ˟˟˟˟
And Im kinda stumped for a solution

pics to show whats where.......



^^ Full rig weight on springs
(Yes Im missing 250lbs in parts, my #325 buddy makes it squat 3/4" tops...




^^ INSTALLED POSITION
(Passenger side frame tube is within 1/8" of drivers, so its "CLOSE"!!!)




^^ I assume I have the springs correctly....

ANY HELP WOULD BE GREAT
At this point my gut tells me my frame tubes are going to need to move forward....

dub tek

At this point
I cant mount my shock hoops till I get my ride height proper
So Im in a bind and lookn for some info from you pro SAS folks

HighLux

That thing is sweet. Cant wait to see more progress.

Very nice color.

dub tek

Hey thanks man!!!


Tryn to get this thing proper asap
Its about to start snowing..........

dub tek

Finished up all the coolant plumbing
Got the yota power steering line into the vw pump

Getting electricals ready to sort
Printed put a huge copy of the trucks diagram
My plan is to remove all the 22re wiring
While keeping the yota accessories
Wish I knew toyota like I know vw would make this portion of the process WAY easier....

lil_red_yota

Clean truck. Can't wait to see how the vw diesel works out.

dub tek

Thanks man
Im wrenching on it daily till its proper!







Got the coolant system sorted finally
I have the power steering all connected up
Clutch slave functions


Working on:
-Brake booster/master cylinder combo from a taco
-VW fuel filter mount
-VW expansion tank
-VW wiring harness
~Yoyota wiring harness
-dropping the fuel tank and removing the fuel pump (Leaving the sender)
-Turbo Exhaust pipe "Down Pipe"
-Intercooler Mounting + Plumbing (2" > Cooler - 2.5" from cooler to manifold)
-Boost gauge
-Electric Cooling fan & Switch

AND 1200 little other things I dont even know about yet.....
Haha

kornhuskerwizard

Looks awesome.great build!

Gizler00

iTrader: (1)

Wow thats a clean truck!!

Great progress on the build so far. You didnt waste any time at all!!

I dream about owning another diesel...

dub tek

^ Thanks guys

Ive been poking at this on the regular
I finally got to flex the truck a bit
Found the oil pan VS steer bar was an issue
Had to relocate the steering box a bit
(New weld tube in frame and eyelet on top of rail)

This moved the arm forward enough to clear
However I found the drivers side UP travel the leaf hits the drop arm on the box
(Ordering flat arm and this should solve my issue)



This week Ill get the intercooler + Oil cooler mounted up front
ALL my rear end lift parts should be here this week friday too
So ill finally be able to get the steering/suspension sorted out for now....


MOAR pics to follow

dropzone

iTrader: (6)

Sweet..just noticed Acme Adapters is in Portland. . Might give them a call to see how this conversion works with Oregon DEQ.

Anything different you have to do with the fuel tank? Or just use the stock fuel pump etc?

dub tek

Yep Acme is GREAT!!


Yes & No
In my past gas>diesel swap experiences I have removed the electric in tank pump as the diesel pump is mechanical pull from the tank...

Now some folks will add an external inline "stepper" pump (Low psi)
Be aware some CARB type fuel pumps can have issues with diesel fuel so check for diesel compatibility if you decide to use a stepper...
you dont want your mechanical pump sucking electric pump seals/parts.. LOL


As far as the tank goes
its just drop down > remove the pump > reinstall it

dub tek

Got some rear lift installed

Still a bit rear end low tho...
but the springs are stiff so it should sag much when she gets loaded

Working on front and rear drive lines now
What joints where
What lengths need cut from what
What I need to buy tubing wise
Still learning this ins/outs

aztoyman

I have the 4"TG kit (3" springs) and my shackles looked the same after the swap. They took forever to settle but they finally did. I actually drove around without shocks and flexed the hell out of it to get it to settle. I even have a HEAVY bumper and winch and now a 3.4.

Drove it a while without bump stops which is a no no. Not supposed to invert the springs. I installed bump stops AFTER it settled.

I now hear that some people recommend putting the frame tubes all the way forward instead of centered between the cab mount like in the instrustions. Too late now.